Led lamp for light source and method

ABSTRACT

Whereas incandescent light bulbs and other similar light sources known in the related art emit light in all directions, LED lamps can emit light in a single direction, and this is manifested in the problem of being unable to achieve light distribution characteristics satisfied by conventional headlamp designs. In accordance with an embodiment of the disclosed subject matter, an LED lamp for a light source of a headlamp can include an LED chip in the vicinity of the focus of a projection means and a shielding member covering a portion of the LED chip in a formation allowing a light distribution characteristic suitable for a vehicle front-illumination light to be obtained when light from the LED chip is magnified and projected in an illumination direction by a projection lens or the like constituting the projection means. Accordingly, accurate light distribution characteristics can be obtained in a simple manner by projecting in the illumination direction using the projection lens.

This application is a Continuation application and claims priority under35 U.S.C. §120 of U.S. patent application Ser. No. 10/662,374 and ofco-pending U.S. patent application Ser. No. 11/283,932, and also claimsthe priority benefit under 35 U.S.C. §119 of Japanese Patent ApplicationNo. 2003-169182 filed on Jun. 13, 2003. The above-referenced prioritydocuments are hereby incorporated in their entirety by reference.

BACKGROUND

1. Field

The disclosed subject matter relates to LED lamps, and in particular, tothe configuration of LED lamps used as light sources in vehicle lights.Furthermore, it relates to the configuration of an LED lamp suitable foruse as a light source in a vehicle lamp for illumination purposes thathas not previously been put to use as headlamps (or headlights),auxiliary headlamps (or fog lights), or the like.

2. Detailed Description of the Related Art

When LED lamps are used as a light source in flashlights and othersimilar lamps for the purpose of illumination in the related art, alarge LED chip is housed in a large package and light amount is obtainedby, for example, applying a current of between several ten and severalhundred milliamperes.

Simultaneously, as the package is made large in size, deterioration orbreakage of the LED chip as a result of overheating is prevented byeffectively conducting the heat emitted in the LED chip to the outsidewhen it is lit and discharging it to the atmosphere or the like. (Forexample, see Patent Document 1)

Patent Document 1

The Japanese Patent Laid-Open No. 2000-150968 (Paragraph 0011 throughParagraph 00.34, FIG. 1)

Nevertheless, when a light fixture using an LED lamp as a light sourceis employed as a vehicle lamp fixture for a headlamp or the like, strictlight distribution characteristics are set forth in relevant standardsand other regulations with regard to prevent the drivers of oncomingvehicles from being dazzled by the light directed forwards. Furthermore,the configuration of lamps for the headlamp or the like is establishedin consideration of incandescent light bulbs and other similar itemsemitting light flux uniformly in almost all directions. Consequently,problems exist in that light distribution characteristics and the likecannot be satisfied by simply replacing the lamp with an LED lampradiating light in a single direction in a relatively large amount.

SUMMARY

As a tangible means of resolving the problems known in the related art,an LED lamp for a light source of a headlamp can be characterized inthat an LED chip or a white LED light emission portion comprising an LEDlamp and fluorophor is disposed in the vicinity of the focus of aprojection means, and a shielding member covering a portion of the whiteLED light emission portion is provided in a formation allowing a lightdistribution characteristic suitable for a vehicle headlamp to beobtained when light from the white LED light emission portion ismagnified and projected in an illumination direction by the projectionmeans. Accordingly, the problems are resolved by enabling the regulatedlight distribution characteristics to be accurately and easily achievedeven when an LED lamp is used as a light source.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics, features and advantages of thedisclosed subject matter will become clear from following descriptionwith reference to the accompanying drawing, wherein:

FIG. 1 is a perspective view showing an LED lamp for a light source of aheadlamp according to an embodiment of the disclosed subject matter.

FIG. 2 is a cross-section view on A-A of FIG. 1.

FIG. 3 is an explanatory drawing showing a typical passing lightdistribution characteristic obtained by an embodiment of the disclosedsubject matter.

FIG. 4 is an explanatory drawing showing an embodiment of the LED lampfor the light source of the headlamp according to the disclosed subjectmatter when a projection lens is assembled thereto.

FIG. 5 is a cross-section view showing a typical configuration of ashielding member in the LED lamp for a light source of a headlampaccording to an embodiment of the disclosed subject matter.

FIG. 6 is an explanatory drawing showing typical chromatic aberrationoccurring in a projection lens.

FIG. 7 is a cross-section view showing another typical configuration ofthe shielding member in the LED lamp for the light source of theheadlamp according to an embodiment of the disclosed subject matter.

FIG. 8 is a cross-section view showing a further typical configurationof the shielding member in the LED lamp for the light source of theheadlamp according an embodiment of the disclosed subject matter.

FIG. 9 is an explanatory drawing showing a typical configuration of theheadlamp light when a plurality of LED lamps for the light source of theheadlamp and projection lenses are combined.

FIG. 10 is an explanatory drawing showing a typical shaping method for alight distribution characteristic when a plurality of LED lamps for thelight source of the headlamp and projection lenses are combined.

FIG. 11 is an explanatory drawing showing a configuration when the LEDlamp for the light source of a headlamp according to an embodiment ofthe disclosed subject matter is combined with a reflector.

REFERENCES

-   -   1: LED lamp for a light source of a headlamp    -   2: LED chip    -   3: Base unit    -   3 a: Base    -   3 b: Lead frame    -   3 c: Insulating layer    -   4: Metal wire    -   5: Fluorophor    -   6: Window glass member    -   7: Shielding member    -   7 a: Serrated section    -   8: White LED light emission portion    -   9: Silicone gel    -   10: Projection lens    -   11: Reflector    -   12: SiO₂ film

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Hereinafter, the disclosed subject matter will be described by way ofexemplary embodiments thereof with reference to the accompanyingdrawings. The part indicated by reference 1 in FIG. 1 and FIG. 2 is anLED lamp for a light source of a headlamp according to an embodiment ofthe disclosed subject matter (hereinafter referred to as an “LED lamp1”), and in the LED lamp 1, an LED chip 2 is mounted on a base unit 3.

The base unit 3 provides a base 3 a formed with a metal member of copperor some other metal excellent in heat conduction and a lead frame 3 balso formed with a metal member. The base 3 a and the lead frame 3 b areinsulated by an insulating layer 3 c formed with a resin member oranother similar insulating member. The LED chip 2 mounted on the base 3a is wired to the lead frame 3 b using a metal wire 4 or the equivalent,so the lighting can be carried out using power supplied from theexterior.

Considering the conditions to be satisfied for usage of the LED lamp 1as a light source for a headlamp, it can be seen that the regulatedcolor of the lamp is white or monochromatic yellow. Although white lightis used more often, no LED chip 2 that can directly emit white lightactually exists, and fluorophor 5 are used in combination in order toobtain white light.

As a first method of doing so, an LED chip 2 generating blue light and awavelength conversion member such as fluorophor 5 emitting yellow lightare combined, and white light is obtained by mixing the blue lightemitted directly from the LED chip 2 with the yellow light emitted fromthe fluorophor 5 excited by the light from the LED chip 2. As a secondmethod, furthermore, the LED chip 2 emitting ultra-violet light iscombined with fluorophor 5 emitting light of the three primaries red(R), green (G), and blue (B). In this case, the light emitted directlyfrom the LED chip 2 is not used as illumination light, and theillumination light from the LED lamp 1 comprises the light emitted fromthe fluorophor 5.

An embodiment of the disclosed subject matter will hereinafter bedescribed in terms of a light source for a headlamp using a white LEDlight emission portion 8 combining an LED chip 2 and fluorophor 5;nevertheless, in situations where it is required that the lamp color beyellow, for example, it is possible for the light emitted directly fromthe LED chip 2 to be used as the light for the light source. In such asituation, however, it is also possible for the embodiment of thedisclosed subject matter to be implemented, and it is sufficient for thewhite LED light emission portion 8 to be replaced by the LED chip 2 inthis case.

Parts such as the LED chip 2, a metal wire 4, and fluorophor 5 aremechanically weak and do not have good resistance to humidity and othersimilar factors. Accordingly, these parts are covered by a lens-shapedmember formed from transparent resin or the like or by a window glassmember (the accompanying drawings show an example in which a windowglass member 6 is used), and through the action of this part and thebase 3 a, are sealed with respect to outside air. Thus, theabove-described parts are prevented from breaking as a result of contactwith the other parts, deteriorating as a result of humidity, and othersimilar factors. Furthermore, it is possible to fill inert gas, siliconegel, or the like (this explanation assumes usage of silicone gel 9) intothe space between the lens-shaped member or the window glass member andthe white LED light emission portion 8.

In addition, the LED lamp 2 according to an embodiment of the disclosedsubject matter provides a shielding member 7. Furthermore, thisshielding member 7 covers a portion of the fluorophor 5, and forexample, when light emitted from the fluorophor 5 is projected in theillumination direction by a projection lens or the like, allows a lightdistribution pattern for passing or any other desired light pattern tobe obtained.

Accordingly, both the window glass member 6 and the shielding member 7are disposed more forward than the fluorophor in the illuminationdirection, and since the window glass member 6 is transparent and theshielding member 7 is opaque, either of these parts can be disposedforward of the other. Furthermore, the shielding member 7 can be freelyformed, for example, using the inner and outer surfaces of the windowglass member 6 with an opaque paint covering or vapor deposition ofmetallic member.

When a headlamp using the LED lamp 1 as a light source is used toprovide light for an infrared night-vision device, a member transmittingthe infrared light and shielding visible light-is used for the windowglass member 6, and in terms of the shielding member 7, it is sufficientto use a member shielding beam of light from infrared through visiblelight. Moreover, when the shielding member 7 is a vapor deposited filmwith the metallic member, deterioration as a result of oxidation andother similar factors are considered possible, and therefore, it isacceptable to provide protection by covering with a SiO₂ film asindicated by reference 12 in FIG. 2.

Reference HB from FIG. 3 indicates a typical passing light distributionpattern for left-hand drive situations. In this passing lightdistribution pattern HB, the half on the right of the vehicle centerlineconstitutes a light distribution pattern containing no upward directedlight in order to prevent the drivers of oncoming vehicles from beingdazzled. On the other hand, the half on the left of the vehiclecenterline contains a section called an “elbow” in which upward directedlight increases towards the left at an angle of 15.degree. in order toallow traffic signs and the like on the road side to be easilyidentified.

In an embodiment of the disclosed subject matter, the shape of theportion of the fluorophor 5 not covered by the shielding member 7 ismade similar to that of the above-mentioned passing light distributionpattern HB. Moreover, as shown in FIG. 4, the shape of the fluorophor 5obtained in this way is projected in the illumination direction P by aprojection lens 10 to obtain the passing light distribution pattern HB.In order to ensure that highest intensity is in the front horizontaldirection so that good long-distance visibility can be assured, when theLED chip 2 is covered by the shielding member 7, this is performed atthe point of highest intensity or at a position in the vicinity thereof.

Horizontal and vertical inversion occurs after projection by theprojection lens 10, and therefore, the LED lamp 1 is mounted in theheadlamp in a 180.degree.-rotated condition, and when projection iscarried out by the projection lens 10 in this condition, an erect imageof the passing light distribution pattern HB can be obtained.Furthermore, by modifying the formation of the shielding member 7, lightdistribution patterns without an elbow, light distribution patterns fordriving, and other types of light distribution pattern can be freelyformed.

As a further description of the shielding member 7, it can be statedthat since the shielding member 7 shields the light from the LED chip 2,when half thereof is covered, the quantity of light is halved, and inthis way, loss occurs with respect to the quantity of light emitted fromthe LED chip 2. The results of studies by the inventors show that thetreatment of the surface at least opposing the LED chip 2 has a minoreffect on the shape of the light distribution characteristic formedafter projection.

That is to say, when the surface of the shielding member 7 (i.e., thesurface facing the projection lens 10) reflects light, this light isre-projected by the projection lens 10 and there is a high probabilitythat formation of the light distribution pattern will be adverselyaffected. Therefore, it may be helpful to provide non-reflectiontreatment of a color such as black. Nevertheless, a mirror finish isprovided to the rear surface, and even when the light emitted from theLED chip 2 is reflected, this light can substantially return only to theLED chip 2 side and has no substantial effect on the formation of theboundary between the fluorophor 5 and the shielding member 7, or inother words, on the formation of the shape of the light distributioncharacteristic.

The light reflected by the rear surface of the shielding member 7 isreturned to the inside of the fluorophor 5. Therefore, by providing, asshown in FIG. 5, a mirror finish on the rear surface of the shieldingmember 7 and, for example, a serrated section 7 a emitting light to bereflected in the direction of the non-covered portion of the fluorophor5, the brightness of light from the fluorophor 5 can be improved. Inother words, the light reaching the rear surface of the shielding member7 can be collected for use as illumination light, and it has beenconfirmed by trial manufacture and measurement by the inventors that thequantity of light increases by at least 15%.

Furthermore, results of simultaneous studies carried out by theinventors regarding the shielding member 7 showed that it is sometimeshelpful to perform projection with the focus of the projection lens 10aligned with the shielding member 7 in order to enable more preciseformation of the shape of the light distribution characteristic.Moreover, when brightness is required within the light distributioncharacteristic, it is possible to perform projection with the focus ofthe projection lens 10 aligned with the white LED light emission portion8 (or LED chip 2 when the lamp color is yellow). If the LED chip 2 andthe shielding member 7 are disposed in mutual proximity, the focus issubstantially aligned with both parts, and this condition is favorablein terms of both shape and brightness. Furthermore, a gap between bothof these parts of 2 mm or less may be helpful, and even better resultsmay be possible by reducing this gap to 1 mm or less.

In situations as explained above where the white LED light emissionportion 8 covered by the shielding member 7 is projected by theprojection lens 10, a single plano-convex lens is often used for theprojection lens 10. Therefore, as shown in FIG. 6, a difference occursin the position of, for example, the focus fb for blue light and thefocus fr for red light, resulting in what is known as chromaticaberration.

In such a case, if the shielding member 7 is disposed closer to any oneof such foci, coloration occurs in the terminator HL (see FIG. 3)corresponding to the portion of the passing light distribution patternHB in which the shape of the shielding member 7 is projected, and it istherefore impossible to satisfy the regulation requiring that the lightcolor be monochromatic. As a means of solving this problem, if thethickness t of the shielding member 7 is, for example, made to extendfrom the focus fb for the blue light to the focus fr for the red lightas shown in FIG. 7, and a plurality of colors are emitted on theprojected terminator HL, the color of the light emitted when this pluralcolors are mixed is close to white. Thus, it is possible to eliminate asense of specific colors being present.

Alternatively, as shown in FIG. 8, two or more thin shielding members 7are provided, and for example, the front and rear surfaces of the windowglass member 6 is used; furthermore, one of these thin shielding members7 is disposed at the position of the focus fb for the blue light, andthe other is disposed at the position of the focus fr for the red light.In accordance with this configuration, the blue light and the red lighthaving a substantially complimentary-color relationship are mixed on theprojected terminator HL of the passing light distribution pattern HB,and in the same way as explained above for the thick shielding member 7,it is possible to eliminate a sense of specific colors being present.

As a further description of the shielding member 7, it can be statedthat in addition to the chromatic aberration described above, aberrationfactors such as spherical aberration, astigmatism, coma, fieldcurvature, and distortion occur in the projection lens 10. As a resultof these aberration factors, shape distortion or focus displacementoccurs when the shape of the white LED light emission portion 8 isprojected.

Therefore, if the shielding member 7 is formed with the same curvatureas the curvature in the focus surface of the projection lens 10 in orderto countermeasure field curvature for example, it is possible to obtaina sharp terminator HL extending from the center to the right and left(provided that spherical aberration, astigmatism, and coma have noeffect). Furthermore, in response to distortion and other aberrationfactors that cause shapes to become distorted, it is sufficient tocorrect the shielding member 7 in such a way that the desired shape ofthe passing light distribution pattern is obtained after projection.

As explained above, all aberration factors can be resolved by methodssuch as thickening, curving, or transforming of the shielding member;however, no detailed explanation of these methods will be providedherein as such information is already publicly known in terms of a widerange of projector-type lamps using projector lenses 10.

FIG. 9 shows a schematic representation of another embodiment of aheadlamp lamp using an LED lamp 1 as a light source according to thedisclosed subject matter.

FIG. 4 showed an illumination-lamp configuration comprising a single LEDlamp 1 and a single projection lens 10; however, while the white LEDlight emission portion 8 containing the shielding member 7 satisfies theregulations for the passing light distribution pattern HB in terms ofshape, the illumination distribution provides insufficient centralillumination and other similar regulations may not be satisfied.

Here, as the white LED light emission portion 8 with an extremely smallsurface area is directly projected, the projection lens 10 may also besmall. Accordingly, even if a plurality of combinations of an LED lamp 1and the projection lens 10 are provided, the dimensional requirementsfor a headlamp can be satisfied.

Accordingly, this embodiment sets the plurality of combinations of theLED lamp 1 and the projection lens 10 to, for example, three for asingle illumination lamp. In this case, the LED lamp 1 can be from thesame one used in the previous embodiment. However, as for the projectionlens 10, a No. 1 projection lens 10 a with a same magnification as theprojection lens 10 used in the FIG. 4, a No. 2 projection lens 10 b witha reduced magnification, and a No. 3 projection lens 10 c with a furtherreduced magnification are provided. All of these projection lensesperform projection in the same direction.

FIG. 10 shows the passing light distribution pattern HBs obtained from aheadlamp configured as explained above. Although this passing lightdistribution pattern HBs is same to the passing light distributionpattern HB (see FIG. 3) from the previous embodiment in terms of shape,it is formed into a prescribed shape by superimposing the lightdistribution pattern Ha from the No. 1 projection lens 10 a, the lightdistribution pattern Hb from the No. 2 projection lens 10 b, and thelight distribution pattern Hc from the No. 3 projection lens 10 a-c.

Accordingly, the light distribution pattern Hc from the No. 3 projectionlens 10 c having the lowest magnification is the brightest. Moreover, bydisposing this light distribution pattern Hc in the central area of thepassing light distribution pattern HBs, illumination for the frontdirection of a vehicle becomes brightest and long-distance visibility isimproved. Furthermore, regulations can be satisfied by adjusting themultiplicity of combinations of an LED lamp 1 and a projection lens 10and the magnification of the corresponding projection lenses 10 c.

In general, the quantity of light obtained from the LED lamp 1 is smallin comparison with that of the halogen bulbs and metal halide dischargedlamps used as light sources in the related art. Therefore, such a methodof increasing the number of combinations and the quantity of light isvery effective as a means of realizing the headlamp using the LED lamp 1as a light source.

In order to simplify the above explanation, the embodiment obtains thefinal passing light distribution pattern by superimposing a plurality oflight distribution patterns having a substantially identical shape anddifferent magnifications. However, the final passing light distributionpattern may be formed by joining a plurality of elements suitablydividing the shape of the final passing light distribution pattern. Inother words, it is sufficient to ultimately obtain the lightdistribution pattern that satisfies the regulations.

FIG. 11 shows an example of another projection method using the LED lamp1 according to an embodiment of the disclosed subject matter. In thisexample, projection in the illumination direction P is carried outusing, for example, a reflector 11 having a paraboloid of revolutionshape or another similar shape having a focus instead of the projectionlens 10 constituting the previous projection means, thus realizing anillumination light with the prescribed light distribution pattern.

Accordingly, this projection method using the reflector 11 forming aprojection image using the reflected light disposes the LED chip 2, thefluorophor 5, the shielding member 7, and the like in opposition to thereflector, or in other words, the parts are disposed in proximitythereto facing approximately backward with respect to the illuminationdirection P.

If this reflector 11 is, for example, a multi-reflector combining aplurality of parabolic adjustable surfaces, a high degree of freedom isachieved when forming the passing light distribution pattern HB, andsince the chromatic aberration does not fundamentally occur in thereflector 11, the high quality passing light distribution pattern HB canbe easily obtained. Furthermore, as in the case of the projection lensexplained above, a plurality of combinations of the LED lamp 1 and thereflector 11 can be used in the realization of the headlamp.

As explained above, an LED lamp for a light source of a headlamp caninclude an LED chip in the vicinity of the focus of a projection meansand a shielding member covering a portion of the LED chip in a formationallowing a light distribution characteristic suitable for a headlamp ofa vehicle to be obtained when light from the LED chip is magnified andprojected in an illumination direction by the projection means.Accordingly, light distribution shapes with accurate characteristics canbe obtained in an extremely simple manner by projecting the shape of thelight emission portion of the solid construction constituted by the LEDlamp for a light source of a headlamp in the illumination directionusing a projection lens or a reflector, and thus, exceptional advantagesare achieved in the form of reliability improved by the solid statelight source, cost reduction by the simplified construction, and theability for compact designs.

While exemplary embodiments of the present invention have been shown anddescribed, it will be understood that the present invention is notlimited thereto, and that various changes and modification may be madeby those skilled in the art without departing from the scope of theinvention as set forth in the appended claims.

1. An LED lamp comprising: a first base unit; a first LED chip capableof emitting a first light and located in the base unit; a firstshielding member located adjacent a portion of said first LED chip, thefirst shielding member forming a first window having a first shape suchthat the first light is emitted from the lamp via the first window ofthe first shielding member and having a shape defined by the firstshape; a first light distribution characteristic forming structurelocated adjacent the first shielding member and configured to cause thefirst light to have a first light distribution characteristic whenemitted from the lamp; a second base unit; a second LED chip capable ofemitting a second light and located in the second base unit; a secondshielding member located adjacent a portion of said second LED chip, thesecond shielding member forming a second window having a second shapesuch that the second light is emitted from the lamp via the secondwindow of the second shielding member and having a shape defined by thesecond shape; and a second light distribution characteristic formingstructure located adjacent the second shielding member and configured tocause the second light to have a second light distributioncharacteristic when emitted from the lamp, wherein the first lightdistribution characteristic is different from the second lightdistribution characteristic.
 2. The LED lamp of claim 1, wherein the LEDlamp is a vehicle headlamp.
 3. The LED lamp of claim 1, wherein thefirst light distribution characteristic forming structure is aprojection lens.
 4. The LED lamp of claim 1, wherein the first lightdistribution characteristic forming structure is a reflector.
 5. The LEDlamp of claim 1, wherein a surface of said first shielding member facingtowards the first LED chip has a substantially mirrored finish.
 6. TheLED lamp of claim 1, wherein the first light distribution characteristicis a first magnification, and the second light distributioncharacteristic is a second magnification, and the first magnification isdifferent from the second magnification.
 7. The LED lamp of claim 1,further comprising: a wavelength conversion material located above thefirst LED chip, the first base unit integrally connected with thewavelength conversion material and first shielding member, wherein thefirst base unit forms an aperture and the shielding member andwavelength conversion material are located within the aperture of thefirst base unit.
 8. The LED lamp of claim 1, further comprising: anintegral one piece lead extending into and from the first base unit; anda bonding wire directly connected to the one piece lead and to the firstLED chip.
 9. An LED lamp comprising: a first base unit; a first LED chipconfigured to emit a first light, the first LED chip being located inthe first base unit; a first shielding member located adjacent a portionof said first LED chip, the first shielding member forming a firstwindow having a first shape such that the first light is emitted fromthe lamp via the first window of the first shielding member and having ashape defined by the first shape; a first light distributioncharacteristic forming structure located adjacent the first shieldingmember and configured to cause the first light to have a first lightdistribution characteristic when emitted from the lamp; a second baseunit; a second light source configured to emit a second light, thesecond light source being located in the second base unit; a secondshielding member located adjacent a portion of said second light source,the second shielding member forming a second window having a secondshape such that the second light is emitted from the lamp via the secondwindow of the second shielding member and having a shape defined by thesecond shape; and a second light distribution characteristic formingstructure located adjacent the second shielding member and configured tocause the second light to have a second light distributioncharacteristic when emitted from the lamp, wherein the first lightdistribution characteristic is different from the second lightdistribution characteristic.
 10. The LED lamp of claim 9, wherein theLED lamp is a vehicle headlamp.
 11. The LED lamp of claim 9, wherein thefirst light distribution characteristic forming structure is aprojection lens.
 12. The LED lamp of claim 9, wherein the first lightdistribution characteristic forming structure is a reflector.
 13. TheLED lamp of claim 9, wherein a surface of said first shielding memberfacing towards the first LED chip has a substantially mirrored finish.14. The LED lamp of claim 9, wherein the first light distributioncharacteristic is a first magnification, and the second lightdistribution characteristic is a second magnification, and the firstmagnification is different from the second magnification.
 15. The LEDlamp of claim 9, further comprising: a wavelength conversion materiallocated above the first LED chip, the first base unit integrallyconnected with the wavelength conversion material and first shieldingmember, wherein the first base unit forms an aperture and the shieldingmember and wavelength conversion material are located within theaperture of the first base unit.
 16. The LED lamp of claim 9, furthercomprising: an integral one piece lead extending into and from the firstbase unit; and a bonding wire directly connected to the one piece leadand to the first LED chip.
 17. A method for using an LED lampcomprising: providing a first base unit and a first LED chip located inthe first base unit and capable of emitting a first light; providing afirst shielding member located adjacent a portion of said first LEDchip, the first shielding member forming a first window having a firstshape such that the first light is emitted from the lamp via the firstwindow of the first shielding member and having a shape defined by thefirst shape; providing a first light distribution characteristic formingstructure located adjacent the first shielding member and configured tocause the first light to have a first light distribution characteristicwhen emitted from the lamp; providing a second base unit and a secondlight source located in the second base unit and configured to emit asecond light; providing a second shielding member located adjacent aportion of said second light source, the second shielding member forminga second window having a second shape such that the second light isemitted from the lamp via the second window of the second shieldingmember and having a shape defined by the second shape; providing asecond light distribution characteristic forming structure locatedadjacent the second shielding member and configured to cause the secondlight to have a second light distribution characteristic when emittedfrom the lamp, wherein the first light distribution characteristic isdifferent from the second light distribution characteristic; emittinglight from the first base unit and second base unit; and combining thefirst light from the first base unit with the second light from thesecond base unit to provide a light that has a light distributioncharacteristic that is different from either of the first lightdistribution characteristic or the second light distributioncharacteristic alone.
 18. The method for using an LED lamp of claim 17,further comprising: configuring the lamp as a vehicle headlamp.
 19. TheLED lamp of claim 17, wherein providing the first light distributioncharacteristic forming structure includes providing a projection lens.20. The LED lamp of claim 17, wherein providing the first lightdistribution characteristic forming structure includes providing areflector.